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EP3416916B1 - Configuration de la synthèse de nh3 pour de grandes installations - Google Patents

Configuration de la synthèse de nh3 pour de grandes installations Download PDF

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Publication number
EP3416916B1
EP3416916B1 EP17722691.7A EP17722691A EP3416916B1 EP 3416916 B1 EP3416916 B1 EP 3416916B1 EP 17722691 A EP17722691 A EP 17722691A EP 3416916 B1 EP3416916 B1 EP 3416916B1
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EP
European Patent Office
Prior art keywords
synthesis gas
catalyst bed
heat exchanger
product
gas
Prior art date
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Application number
EP17722691.7A
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German (de)
English (en)
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EP3416916A1 (fr
Inventor
Christoph Meissner
Andreas KINNER
Klaus NÖLKER
Reinhard Heun
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
ThyssenKrupp AG
ThyssenKrupp Industrial Solutions AG
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ThyssenKrupp AG
ThyssenKrupp Industrial Solutions AG
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Publication of EP3416916A1 publication Critical patent/EP3416916A1/fr
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    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01C—AMMONIA; CYANOGEN; COMPOUNDS THEREOF
    • C01C1/00—Ammonia; Compounds thereof
    • C01C1/02—Preparation, purification or separation of ammonia
    • C01C1/04—Preparation of ammonia by synthesis in the gas phase
    • C01C1/0405—Preparation of ammonia by synthesis in the gas phase from N2 and H2 in presence of a catalyst
    • C01C1/0417—Preparation of ammonia by synthesis in the gas phase from N2 and H2 in presence of a catalyst characterised by the synthesis reactor, e.g. arrangement of catalyst beds and heat exchangers in the reactor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J8/00—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
    • B01J8/02—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds
    • B01J8/04—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds the fluid passing successively through two or more beds
    • B01J8/0492—Feeding reactive fluids
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J8/00—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
    • B01J8/02—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds
    • B01J8/04—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds the fluid passing successively through two or more beds
    • B01J8/0496—Heating or cooling the reactor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2208/00—Processes carried out in the presence of solid particles; Reactors therefor
    • B01J2208/00008—Controlling the process
    • B01J2208/00017—Controlling the temperature
    • B01J2208/00106—Controlling the temperature by indirect heat exchange
    • B01J2208/00168—Controlling the temperature by indirect heat exchange with heat exchange elements outside the bed of solid particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2208/00—Processes carried out in the presence of solid particles; Reactors therefor
    • B01J2208/02—Processes carried out in the presence of solid particles; Reactors therefor with stationary particles
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P20/00—Technologies relating to chemical industry
    • Y02P20/50—Improvements relating to the production of bulk chemicals
    • Y02P20/52—Improvements relating to the production of bulk chemicals using catalysts, e.g. selective catalysts

Definitions

  • the invention relates to a method and a device for producing ammonia from a synthesis gas under heterogeneous gas catalysis in at least two reaction devices connected in series, each of these reaction devices each comprising at least two catalyst beds through which the synthesis gas is passed and in which an at least partial reaction to Product gas is provided, wherein at least a first heat exchanger is provided in the first reaction device in which the fresh synthesis gas A is preheated and wherein cooling of the effluent from the first catalyst bed synthesis gas B comprising product and unreacted reactants is provided prior to entry into the second catalyst bed ,
  • a number of products in the basic industries, such as Ammonia or methanol are synthesized in large scale gas catalysis using fixed bed catalysts.
  • the syntheses usually proceed at volume decrease under very high working pressures at high working temperatures.
  • the synthesis gas contains hydrogen and nitrogen and possibly also inert gases such as methane and / or noble gases.
  • inert gases such as methane and / or noble gases.
  • a separation system is provided, with which the generated ammonia is removed from the circulation in liquid form.
  • the ammonia-forming reaction is a pronounced equilibrium reaction, the equilibrium position of which moves more and more to the side of the reactants with increasing temperature.
  • the equilibrium position In the range of the usual operating temperatures of the catalyst beds and working pressures of about 200 bar, only ammonia equilibrium concentrations of 20-25% are achieved.
  • Le Chatelier by increasing the working pressure, the equilibrium position can be shifted to higher ammonia concentrations.
  • An increase in the synthesis pressure are set by the available compressors narrow limits.
  • the additional compressor work has a negative effect on the process efficiency and the higher working pressure requires larger wall thicknesses of the apparatus and thus specifically higher production costs.
  • ammonia formation reaction is highly exothermic, so that the temperature of the process gas continuously increases as it passes through the catalyst bed, when no heat removal is performed.
  • Ammonia synthesis converters with internal bed cooling have been proposed and in some cases also realized. But they are structurally complex and therefore expensive to manufacture. In addition, the filling and removal of the catalyst designed much more complex than reactors without cooling internals in the beds.
  • DE 100 57 863 A1 discloses a process for the production of ammonia from synthesis gas, which contains in addition to the reactants hydrogen and nitrogen inert constituents, in at least two reaction systems, wherein the synthesis of ammonia from synthesis gas is carried out successively in different synthesis systems, wherein in all synthesis systems from each part of the synthesis gas ammonia generated and of which a part is discharged.
  • DD 225 029 relates to a process for the synthesis of ammonia from inert synthesis gas, which by the use of two Reaction systems is characterized. In the first reaction system, only fresh synthesis gas is reacted. The unreacted synthesis gas is fed together with the gas of a synthesis loop to the second reaction system, where the further conversion to ammonia takes place.
  • waste heat from the reaction is used immediately after the ammonia reactor to generate steam or to feed boiler water.
  • the waste heat increases with the production volume of ammonia and the amount of circulation in the synthesis cycle.
  • U.S. Patent 7,683,099 B2 describe processes for carrying out exothermic gas phase reactions with heterogeneous catalysis, in which two reaction devices are used with a total of three catalyst beds, wherein in one of the reaction devices two Katalyatorbetten are arranged.
  • a variant is described in which a partial stream of the product gas separated after passage through the second catalyst bed, strongly cooled and the ammonia condensed out as a product and discharged from the plant. A partial flow of the highly cooled gas is then passed into a second reaction apparatus in which there is a third catalyst bed.
  • a disadvantage of this approach is that the gas must be reheated prior to introduction into the third catalyst bed to initiate the reaction, so that heat energy is lost.
  • the investment costs for this variant are significantly higher, since additional equipment is required for cooling and reheating.
  • the method according to U.S. Patent 7,683,099 B2 comparatively uneconomical.
  • the preheating of the fresh synthesis gas A takes place in a first heat exchanger, which is arranged between the first and the second catalyst bed.
  • the solution according to the invention has the particular advantage that one can use the waste heat of the first catalyst bed for the preheating of the fresh synthesis gas and thus avoids the disadvantages of the quench stream, which in the U.S. Patent 5,352,428 is available.
  • the conversion of the synthesis can be increased without substantial increase in the amount of process gas and with constant catalyst volume.
  • the cooling of the synthesis gas B emerging from the first catalyst bed before entering the second catalyst bed by means of the first heat exchanger, which is arranged in the flow path with respect to the synthesis gas B comprising a proportion of product between the first and the second catalyst bed.
  • the invention provides that an intermediate heat exchanger (2-1) arranged in the flow path between the first reaction device (1) and the second reaction device (3) is provided and the hot product gas stream leaving the second catalyst bed (1-B) without prior cooling Generation of steam in the intermediate heat exchanger (2-1) is used.
  • an intermediate heat exchanger (2-1) arranged in the flow path between the first reaction device (1) and the second reaction device (3) is provided and the hot product gas stream leaving the second catalyst bed (1-B) without prior cooling Generation of steam in the intermediate heat exchanger (2-1) is used.
  • the invention further provides that a cooling of the process gas stream D in the intermediate heat exchanger (2-1) below the inlet temperature required for a subsequent third catalyst bed (3-A), and possibly also below the temperature of the steam generated to the maximum use of energy of stream D , is carried out in a subsequent step, the process gas stream by means of another heat exchanger (3-2), which also serves as an intercooler between the third catalyst bed and a fourth catalyst bed, back to a defined optimum process temperature for the catalyst bed (3-B ) bring to.
  • This allows optimum temperature control over all catalyst beds.
  • step c) the synthesis gas D leaves the intermediate heat exchanger (2-1) at a temperature T A ; and in step d 3 ), the synthesis gas E enters the third catalyst bed (3-A) at a temperature T E ; wherein the temperature T E by at least 30 ° C, preferably by at least 50 ° C is greater than the temperature T A.
  • This temperature difference is then optionally compensated by preheating in step d 1 ) and heating in step d 2 ).
  • T E preferably lies in the range from 360 ° C. to 430 ° C., preferably in the range from 380 ° C. to 420 ° C.
  • An enlarged intercooler removes more heat from the process gas, which can then be used for boiler feedwater pre-heating and / or steam production.
  • the optimum inlet temperature is restored to the subsequent catalyst bed.
  • the exiting process gas from the third catalyst bed can be cooled. In this way, the inlet temperature can be optimally adjusted for the subsequent fourth catalyst bed, resulting in an increased sales results.
  • the reactants in the fresh synthesis gas A comprise hydrogen and nitrogen in a molar ratio of 2.0-4.0: 1.0.
  • the synthesis gas E is cooled in the third heat exchanger (3-2) in order to achieve a higher conversion in the fourth catalyst bed (3-B).
  • the dissipated heat from the synthesis gas F in the third heat exchanger is fed to the synthesis gas E.
  • the synthesis gas D in the first intermediate heat exchanger must be cooled down further than in previous concepts. Due to the greater cooling of the synthesis gas D , it is possible to generate more steam in the first intermediate heat exchanger, which increases the overall energy efficiency of the process.
  • a fresh synthesis gas A comprising reactants and optionally inert components.
  • the inert components are inert with respect to the synthesis of the product.
  • the composition of the fresh synthesis gas A depends on the nature of the product.
  • the inert components preferably comprise noble gases, in particular argon, and also hydrocarbons, in particular methane.
  • the fresh synthesis gas A can come from different sources, with natural gas being the preferred source. With regard to the details for the provision of synthesis gas, for example, fully referenced A. Nielsen, I. Dybkjaer, Ammonia - Catalysis and Manufacture, Springer Berlin 1995, chapter 6, pages 202-326 ,
  • the fresh synthesis gas A provided in step (a) is prepared by reforming hydrocarbons, the reforming being carried out in a steam reformer, in a gas-heated reformer an autothermal reformer or by partial oxidation or the fresh synthesis gas A is produced by electrolysis of water and air separation.
  • Natural gas, water in the form of steam and air or oxygen is preferably used in the reforming.
  • the volumetric proportion of the synthesis gas is preferably hydrogen, wherein the nitrogen content may also be relatively high, depending on whether in the production air, oxygen-enriched air or even pure oxygen was used.
  • the fresh synthesis gas A provided in step (a) may have already undergone conventional work-up procedures, such as helium removal, natural gas desulfurization, conversion of carbon monoxide to carbon dioxide, and carbon dioxide removal. Even after carrying out these treatment measures, the fresh synthesis gas A can comprise, in addition to hydrogen and nitrogen, optionally further, in particular inert components.
  • the synthesis gas A may preferably be fresh, ie according to the invention it may preferably have been previously discharged as purge gas stream from no upstream cycle synthesis.
  • the fresh synthesis gas A provided in step (a) may optionally already be compressed, preferably to a pressure in the range from 50 to 400 bara, more preferably to a pressure in the range from 170 to 230 bara. Also preferably, the fresh synthesis gas A provided in step (a) is compressed in one or more suitable compressors to a pressure in the range of 50 to 400 bara, more preferably to a pressure in the range of 170 to 230 bara.
  • the synthesis of product in step (b) takes place in a single reaction device (1), which is preferably designed as a pressure vessel.
  • the fresh synthesis gas A is preferably introduced into the reaction device (1) at the top end.
  • the fresh synthesis gas A is heated in a first heat exchanger (1-2) and possibly previously in a first preheat exchanger (1-1), preferably at least 20 ° C., more preferably at least 40 ° C. ,
  • the fresh synthesis gas A is passed over a first catalyst bed (1-A) to form a synthesis gas B comprising product and unreacted reactants.
  • the first catalyst bed (1-A) is flowed through by the fresh synthesis gas A predominantly radially, preferably from outside to inside, whereby the thermal load of the pressure vessel is reduced.
  • the choice of catalyst depends on the nature of the product. In terms of According to the invention preferred synthesis of ammonia as a product, for example, magnetite or ruthenium catalysts are suitable, which may optionally be mixed with other components.
  • the synthesis gas B is cooled in the first heat exchanger (1-2), preferably at least 20 ° C, more preferably at least 40 ° C. At least part of the heat of the synthesis gas B is preferably transferred to the fresh synthesis gas A.
  • the nature of the first heat exchanger (1-2) is not limited according to the invention.
  • the first heat exchanger (1-2) is designed as a straight tube heat exchanger with a central tube.
  • a straight pipe heat exchanger is a type of shell and tube heat exchanger. In straight tube heat exchangers, many thin single tubes are being led straight through a large tube. It can be operated both in the DC principle and in the counterflow principle.
  • the straight tube heat exchanger is mainly characterized in that it generates only a very small pressure loss during operation.
  • the synthesis gas B is passed through a second catalyst bed (1-B) to form a synthesis gas C comprising product and unreacted reactants.
  • the second catalyst bed (1-B) is flowed through by the synthesis gas B predominantly radially, preferably from outside to inside.
  • the choice of catalyst depends on the nature of the product.
  • magnetite or ruthenium catalysts are suitable, which may optionally be mixed with other components.
  • the synthesis gas C is then passed over a third catalyst bed (1-C) to form a synthesis gas D comprising product and unreacted reactants.
  • the third catalyst bed (1-C) is flowed through by the synthesis gas C predominantly radially, preferably from outside to inside.
  • the choice of catalyst depends on the nature of the product. With regard to the preferred synthesis of ammonia according to the invention as a product, for example magnetite or ruthenium catalysts are suitable, which may optionally be mixed with other components.
  • a first preheat exchanger (1-1) is used in the process according to the invention, it is preferably also used in step b 6 ) for cooling the synthesis gas D.
  • the first catalyst bed (1-A), the second catalyst bed (1-B) and the possibly present third catalyst bed (1-C) are located in the first reaction device (1) and are preferably arranged one above the other, wherein the first catalyst bed (1 A) is preferably arranged above the second catalyst bed (1-B), which in turn is preferably arranged above the optionally present third catalyst bed (1-C).
  • the synthesis gas D is preferably discharged from the first reaction device (1) at the foot end.
  • step (c) of the process according to the invention at least part of the synthesis gas D is preferably cooled in a first intermediate heat exchanger (2-1).
  • a first intermediate heat exchanger (2-1) Preferably at least 50% by volume of the synthesis gas D in the first intermediate heat exchanger (2-1) is cooled, more preferably at least 60% by volume, at least 70% by volume, at least 80% by volume or at least 90% by volume.
  • at least part of the synthesis gas D in step (c) is cooled by at least 20 ° C, more preferably by at least 30 ° C, at least 40 ° C, at least 50 ° C, at least 60 ° C, at least 80 ° C or at least 100 ° C.
  • step (d) suitable inlet temperatures of the synthesis gas D in the third, fourth and possibly existing further catalyst beds (3-A, 3-B and possibly 3-C) using the third heat exchanger (3 -2). If necessary, this temperature difference is compensated by preheating in step d 1 ) and heating in step d 2 ). Higher sales or plant capacities would therefore not be possible cost-effectively without this step.
  • the first intermediate heat exchanger (2-1) is followed by a second intermediate heat exchanger.
  • the synthesis of product in step (d) is carried out in a single reaction device (3), which is preferably designed as a pressure vessel.
  • the synthesis gas E is preferably introduced into the second reaction device (3) at the top end.
  • the synthesis gas E is heated in a third heat exchanger (3-2), preferably by at least 20 ° C., more preferably by at least 40 ° C.
  • the synthesis gas E is passed through a third catalyst bed to form a synthesis gas F comprising product and unreacted reactants.
  • the third catalyst bed (3-A) is flowed through by the synthesis gas E predominantly radially, preferably from outside to inside.
  • the choice of catalyst depends on the nature of the product. With regard to the preferred synthesis of ammonia according to the invention as a product, for example magnetite or ruthenium catalysts are suitable, which may optionally be mixed with other components.
  • the synthesis gas F is cooled in the third heat exchanger (3-2), preferably at least 20 ° C, more preferably at least 40 ° C. At least part of the heat of the synthesis gas F is preferably transferred to the synthesis gas E.
  • the nature of the third heat exchanger (3-2) is not limited according to the invention. In a preferred embodiment, the third heat exchanger is designed as a straight tube heat exchanger with a central tube.
  • the synthesis gas F is passed through a fourth catalyst bed (3-B) to form a synthesis gas G comprising product and unreacted reactants.
  • the fourth catalyst bed (3-B) is flowed through by the synthesis gas F predominantly radially, preferably from outside to inside.
  • the choice of catalyst depends on the nature of the product. With regard to the preferred synthesis of ammonia according to the invention as a product, for example magnetite or ruthenium catalysts are suitable, which may optionally be mixed with other components.
  • the synthesis gas G is subsequently passed over at least one further catalyst bed (3-C) to form a synthesis gas H comprising product and unreacted reactants.
  • the further catalyst bed is flowed through by the synthesis gas G predominantly radially, preferably from outside to inside.
  • the choice of catalyst depends on the nature of the product. With regard to the preferred synthesis of ammonia according to the invention as a product, for example magnetite or ruthenium catalysts are suitable, which may optionally be mixed with other components.
  • a second preheat exchanger is used in the process according to the invention, it is preferably also used in step d 6 ) for cooling the synthesis gas G.
  • the third catalyst bed (3-A), the fourth catalyst bed (3-B) and any further catalyst bed (3-C) are located in the second reaction apparatus (3) and are preferably arranged one above the other, wherein the third catalyst bed (3 -A) is preferably arranged above the fourth catalyst bed (3-B), which in turn is preferably arranged above the optionally present further catalyst bed (3-C).
  • the synthesis gas H is preferably discharged from the second reaction device (3) at the foot end.
  • step (e) of the method according to the invention at least part of the synthesis gas H is cooled in a first post-heat exchanger (4-1).
  • at least 50% by volume of the synthesis gas H in the first post-heat exchanger is cooled, more preferably at least 60% by volume, at least 70% by volume, at least 80% by volume or at least 90% by volume.
  • at least part of the synthesis gas H in step (e) is cooled by at least 20 ° C, more preferably by at least 30 ° C, at least 40 ° C, at least 50 ° C, at least 60 ° C, at least 80 ° C or at least 100 ° C.
  • the first after-heat exchanger (4-1) is followed by a second after-heat exchanger.
  • the in first intermediate heat exchanger (2-1) and possibly present second intermediate heat exchanger; and or in the first after-heat exchanger (4-1) and possibly existing second secondary heat exchanger dissipated heat is preferably used for the formation of steam, wherein the steam, preferably high-pressure steam can be used either in the method according to the invention or in any other method.
  • first intermediate heat exchanger (2-1) and possibly present second intermediate heat exchanger and or in the first after-heat exchanger (4-1) and possibly existing second secondary heat exchanger Water is introduced, which was preferably previously tempered.
  • at least part of the synthesis gas D in the first intermediate heat exchanger (2-1) and / or at least part of the synthesis gas H in the first post-heat exchanger (4-1) is cooled by at least 50 ° C., more preferably by at least 70 ° C., at least 90 ° C or at least 100 ° C.
  • At least part of the synthesis gas H is circulated after step (e) and mixed with the fresh synthesis gas A provided in step (a).
  • at least 50% by volume of the synthesis gas F or G are circulated, more preferably at least 60% by volume, at least 70% by volume, at least 80% by volume or at least 90% by volume. -%.
  • a synthesis cycle is formed, in which possibly inert components can accumulate.
  • too high a proportion of inert components in the synthesis gas is disadvantageous because it reduces the partial pressure of the reactants and thus the yield of product.
  • the proportion of the synthesis gas H which is conducted in a circuit, is selected so that the proportion of inert components in the synthesis loop is at most 20% by volume, more preferably at most 15% by volume.
  • At least one further heat exchanger (3-2), through which the synthesis gas entering the third catalyst bed (3-A) flows in order to preheat it, is interposed between the third catalyst bed (3) in the second reaction apparatus (3).
  • 3-A) and the fourth catalyst bed (3-B) and this further heat exchanger (3-2) serves simultaneously to cool the synthesis gas F entering the fourth catalyst bed (3-B).
  • the synthesis is on a scale which exceeds a daily production of at least 1,800 t of product, more preferably a daily production of at least 2,500 t of product or of at least 3,000 t of product.
  • a further aspect of the invention relates to a device for the production of ammonia from a synthesis gas A under heterogeneous gas catalysis, in particular for use in a method of the type described above, the device comprising the following interacting components:
  • an intermediate heat exchanger (2-1) configured to cool at least a part of the synthesis gas D ;
  • a after-heat exchanger (4-1) configured to cool at least a portion of the synthesis gas H , wherein according to the invention the first heat exchanger (3-2) is arranged concentrically radially inside the first catalyst bed (3-A) and / or the third heat exchanger (3-3 ) is disposed concentrically radially inside the third catalyst bed (3-B);
  • the components of the device according to the invention are in operative connection with each other, ie by suitable pipes etc. together in one Way connected, which ensures the general functionality of the device.
  • the necessary measures are known to a person skilled in the art.
  • the first (1) and / or the second reaction device (3) preferably comprises a substantially cylindrical container with a vertical longitudinal axis.
  • Reactors for the gas phase reaction at high pressure are known to a person skilled in the art. With regard to the synthesis of ammonia according to the invention, for example, reference is made to A. Nielsen, I. Dybkjaer, Ammonia - Catalysis and Manufacture, Springer Berlin 1995, chapter 6, pages 202-326 ,
  • first intermediate heat exchanger (2-1) and in the first after-heat exchanger (4-1) heat is respectively transferred from the synthesis gas D and / or from the synthesis gas H to water or steam, whereby preferably high-pressure steam> 100 bara is formed, but at least 20 bar of steam.
  • water or steam is introduced into the first intermediate heat exchanger (2-1) and the possibly present second intermediate heat exchanger or in the first reheater (4-1) and the possibly existing second reheat exchanger, which was preferably previously tempered.
  • the means for returning at least part of the synthesis gas H from the first after-heat exchanger (4-1) to the first reaction device (1) preferably comprise suitable pipelines, the configuration of which is known to a person skilled in the art.
  • the amount of water and steam and the temperature for each heat exchanger can each be controlled independently.
  • a first preheat exchanger (1-1) is used in the method according to the invention, then this is preferably also used for cooling the synthesis gas D and configured accordingly.
  • a second preheat exchanger (3-1) is used in the method according to the invention, this is preferably also used for cooling the synthesis gas F and configured accordingly.
  • the first heat exchanger (1-2) in the first reaction device is arranged so that it is first flowed through by the fresh synthesis gas A before it enters the first catalyst bed (1-A) and then preferably in Countercurrent flow from the synthesis gas B leaving the first catalyst bed (1-A) comprising product and unreacted reactants is passed through after leaving the first catalyst bed (1-A) and before entering the second catalyst bed (1-B) ,
  • the third heat exchanger (3-2) is further arranged in the second reaction device (3) so that it first flows through the synthesis gas D leaving the first reaction device (1) before it enters the third catalyst bed (3-A) and that it preferably flows countercurrently from the synthesis gas leaving the third catalyst bed (3-A) comprising product and unreacted reactants after leaving the third catalyst bed (3-A) and before entering the fourth catalyst bed (3-B) is flowed through.
  • the device according to the invention is particularly suitable for carrying out the method according to the invention.
  • a further aspect of the invention therefore comprises the use of the device according to the invention in the method according to the invention.
  • FIG. 1 schematically illustrates a plant according to a first embodiment of the invention, with the aid of which a preferred method according to the invention can be carried out;
  • FIG. 2 shows a schematic view of a plant according to an alternative embodiment of the present invention.
  • FIG. 1 shown variant shows an inventive system with two reaction devices (1), (2), both of which each contain two catalyst beds, so that the system comprises a total of four catalyst beds.
  • a fresh synthesis gas A comprising reactants and optionally inert components is introduced into a first reaction device (1) comprising a first catalyst bed (1-A) and a second catalyst bed (1-B) and a first heat exchanger (1-2).
  • the fresh synthesis gas A Before the fresh synthesis gas A enters the first reaction device (1), it can flow through a pre-heat exchanger (1-1) upstream of the feed line. Thereafter, the fresh synthesis gas A is warmed in the first reaction device (1) in the first heat exchanger (1-2). Subsequently, the warmed fresh synthesis gas A is passed over the first catalyst bed (1-A) to form a synthesis gas B comprising product and unreacted reactants.
  • the first heat exchanger (1-2) is arranged so that it lies radially inwardly within the first catalyst bed (1-A).
  • the catalyst bed (1-A) is annular, located in the first reaction device (1) radially outward and surrounds the first heat exchanger (1-2) annular.
  • the first catalyst bed (1-A) and the heat exchanger (1-2) lying concentrically within it have approximately the same axial length and both extend only over an upper part of the axial length of the first reaction device (1).
  • the flow path of the fresh synthesis gas A is as follows. First, the fresh synthesis gas A enters a straight tube of the first heat exchanger (1-2), which extends centrally approximately in the axial direction in the upper region in the first reaction device (1) and is flowed through by the fresh synthesis gas A from top to bottom. At the lower end there is a reversal of the flow direction and the fresh synthesis gas flows back through the tubes in the first heat exchanger (1-2), where it then flows radially outwards in the direction of the arrows above the first heat exchanger, and then the first catalyst bed ( 1-A) from radially outward to radially inward, whereby the catalytic reaction takes place.
  • the synthesis gas which has been heated by the reaction, flows into the radially inner first heat exchanger (1-2).
  • the synthesis gas is passed so that the heat exchanger is flowed through from top to bottom, where it cools, since a heat exchange with the also flowing through the first heat exchanger cooler fresh synthesis gas A takes place.
  • the synthesis gas leaves the first heat exchanger (1-2) at the lower end to flow radially outward again below the first heat exchanger.
  • the synthesis gas B cooled in the first heat exchanger (1-2) then flows radially from outside to inside in the direction of the horizontal arrows through the second catalyst bed (1-B) to form a synthesis gas D comprising product and unreacted reactants.
  • the first intermediate heat exchanger (2-1) After being discharged from the first reaction apparatus (1), at least part of the synthesis gas D is passed through a first intermediate heat exchanger (2-1) and thereby cooled.
  • the first intermediate heat exchanger (2-1) becomes preferably flows through a boiler feed water, which was previously tempered. In the first intermediate heat exchanger (2-1), heat is transferred from the synthesis gas D to the boiler feed water to form high-pressure steam (5).
  • the cooled synthesis gas E is then introduced into a second reaction device (3) which comprises a third catalyst bed (3-A) and a four-bed catalyst bed (3-B) and a third heat exchanger (3-2).
  • the synthesis gas E is warmed in the third heat exchanger (3-2).
  • the heated synthesis gas E is passed over the third catalyst bed (3-A) to form a synthesis gas F comprising product and unreacted reactants.
  • the construction of the third catalyst bed (3-A) and of the heat exchanger (3-2) associated therewith are in principle analogous to the ratios with respect to the first catalyst bed (1-A) and the first heat exchanger (1-2) assigned to it. This also applies to the spatial arrangement and the flow conditions of the synthesis gas as already explained above.
  • the third heat exchanger (3-2) is thus concentrically within the third catalyst bed (3-A) and is flowed through by the synthesis gas E twice, namely first on the entry of the synthesis gas E in the second reaction device (3) for its heating and also after the reaction in the third catalyst bed for cooling to dissipate the heat generated in the reaction in the catalyst bed.
  • the synthesis gas F is then passed over the fourth catalyst bed (3-B) to form a synthesis gas H comprising product and unreacted reactants.
  • the fourth catalyst bed (3-B) is not directly associated with any further heat exchanger within the reaction apparatus (3) and therefore has a larger radial extent than the third catalyst bed (3-A).
  • the arrangement and the flow conditions correspond to those described above for the second catalyst bed (1-B) and the synthesis gas H leaves the second reaction device (3) in the axial direction at the lower end as indicated by the arrow in FIG. 1 indicated.
  • first post-heat exchanger (4-1) After discharging from the second reaction device (3), at least part of the synthesis gas H is passed through a first post-heat exchanger (4-1) and cooled.
  • the first after-heat exchanger (4-1) is preferably flowed through by a boiler feed water, which was previously tempered.
  • heat is transferred from the synthesis gas H to the boiler feed water to form high pressure steam (5).
  • the third catalyst bed (1-C) in the first reaction device (1) has no associated heat exchanger and may have correspondingly more catalyst volume, as it extends further radially inward.
  • the second reaction device (3) here are also three catalyst beds (3-A), (3-B) and (3-C) are provided, which are arranged in the flow direction of the process gas stream in the second reaction device (3) one behind the other and each in a cylindrical as here reaction device (3) axially follow one another.
  • the total of the fourth catalyst bed (3-A) and the fifth catalyst bed (3-B) heat exchangers (3-2), (3-3) are assigned, which as previously with reference to FIG. 1 are each arranged concentrically within the respective catalyst beds (3-A, 3-B) and are flowed through in the manner described above by the process gas.
  • the third catalyst bed (3-C) in the second reaction device (3) does not have a heat exchanger assigned to it and can correspondingly have more catalyst volume since it extends further radially inwards.
  • a synthesis gas C exits from the second catalyst bed and the first reaction apparatus (1) leaves the synthesis gas stream D after the third catalyst bed (1-C) .
  • a synthesis gas E enters the second reaction apparatus (3) containing the fourth catalyst bed (3-A) leaving the synthesis gas is denoted by F
  • from the fifth catalyst bed (3-B) exits a synthesis gas G and the second reaction device (3) after the sixth catalyst bed (3-C) leaving product gas is designated H.
  • the rest of the system components are in the embodiment according to FIG. 2 formed analogously as already above in the first embodiment according to FIG. 1 described, so that reference is made in this regard to the statements there.
  • the first reaction device (1) according to FIG. 2 carried out that is with three catalyst beds (1-A), (1-B) and (1-C)
  • the second reaction device (3) according to FIG. 1 consist of two catalyst beds, (3-A) and (3-B).
  • the first reaction device (1) according to FIG. 2 that is, with two catalyst beds (1-A) and (1-B)
  • the second reaction device (3) consists of three catalyst beds, (3-A), (3-B), and (3-C).
  • the green curve for the triple converter starts at point 1, where the exothermic reaction begins, product concentration and temperature rise.
  • the catalyst bed flows through, the reaction stops and the gas is cooled at constant concentration to point 3.
  • the gas is passed into the second catalyst bed, concentration and temperature rise again to point 4.
  • the gas is cooled again in a heat exchanger.
  • the gas reacts further up to point 6.
  • the brown curve for the quench reactor is analogous to the green curve, with the difference that the intercooling by the quench gas (point 2 to 3 and point 4 to 5) not only lowers the temperature but also the concentration by adding fresh gas.
  • the blue curve shows the course for the 4-bed reactor described in the invention.
  • the curve in this diagram is also analogous to the other curves. Unlike the other curves, there are 8 vertices on the curve, corresponding to the higher number of beds. It can also be seen from this diagram that the 4-bed reactor produces the highest product concentration at the outlet (top point of the curve) and thus has clear advantages over the other reactor types.

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Claims (18)

  1. Procédé de fabrication d'ammoniac à partir d'un gaz de synthèse sous catalyse gazeuse hétérogène dans au moins deux dispositifs de réaction raccordés en série (1, 3), ces dispositifs de réaction (1) comprenant chacun au moins deux lits catalytiques (1-A, 1-B, 3-A, 3-B), au travers desquels le gaz de synthèse est acheminé et dans lesquels une transformation au moins partielle en gaz de produits a lieu, au moins un premier échangeur de chaleur (1-2) étant prévu dans le premier dispositif de réaction (1), dans lequel le gaz de synthèse frais A est préchauffé, et un refroidissement du gaz de synthèse (B) sortant du premier lit catalytique (1-A) comprenant un produit et des réactifs non réagis étant prévu avant l'entrée dans le deuxième lit catalytique (1-B), le préchauffage ayant lieu dans un premier échangeur de chaleur (1-2) qui est agencé entre le premier (1-A) et le deuxième lit catalytique (1-B), et un échangeur de chaleur intermédiaire (2-1) agencé dans la voie d'écoulement entre le premier dispositif de réaction (1) et le deuxième dispositif de réaction (3) étant prévu, et le courant gazeux de produits chaud sortant du deuxième lit catalytique (1-B) étant utilisé dans l'échangeur de chaleur intermédiaire (2-1) sans refroidissement préalable pour la génération de vapeur et/ou pour le préchauffage d'eau de chaudière, caractérisé en ce qu'un refroidissement d'un courant de gaz de procédé D a lieu dans l'échangeur de chaleur intermédiaire (2-1) en dessous de la température d'entrée nécessaire pour un troisième lit catalytique (3-A) ultérieur, et éventuellement également en dessous de la température de la vapeur générée pour l'utilisation maximale de l'énergie du courant D, afin d'amener de nouveau lors d'une étape ultérieure le courant de gaz de procédé à l'aide d'un échangeur de chaleur supplémentaire (3-2), qui sert simultanément de refroidisseur intermédiaire entre le troisième lit catalytique (3-A) et un quatrième lit catalytique (3-B), à une température de procédé optimale définie pour le lit catalytique (3-A), ce qui permet une régulation de température optimale sur tous les lits catalytiques.
  2. Procédé selon la revendication 1, caractérisé en ce que le refroidissement du gaz de synthèse B sortant du premier lit catalytique (1-A) a lieu avant l'entrée dans le deuxième lit catalytique (1-B) au moyen du premier échangeur de chaleur (1-2), qui est agencé dans la voie d'écoulement au regard du gaz de synthèse B comprenant une fraction de produit entre le premier (1-A) et le deuxième lit catalytique (1-B).
  3. Procédé selon la revendication 1 ou 2, caractérisé en ce que l'ensemble du courant gazeux d'alimentation du gaz de synthèse frais A est acheminé au travers du premier lit catalytique (1-A), puis également au travers du deuxième lit catalytique (1-B).
  4. Procédé selon l'une quelconque des revendications précédentes, caractérisé en ce qu'au moins une partie d'un gaz de synthèse H, qui sort du quatrième lit catalytique (3-B), est mise en circulation dans un circuit et mélangée avec le gaz de synthèse frais A.
  5. Procédé selon l'une quelconque des revendications précédentes, caractérisé en ce qu'au moins un échangeur de chaleur supplémentaire (3-2), qui est traversé par le gaz de synthèse entrant dans le troisième lit catalytique (3-A), afin de préchauffer celui-ci, est agencé dans le deuxième dispositif de réaction (3) entre le troisième lit catalytique (3-A) et le quatrième lit catalytique (3-B), et sert simultanément à refroidir le gaz de synthèse (E) entrant dans le quatrième lit catalytique (3-B).
  6. Procédé selon l'une quelconque des revendications précédentes, caractérisé en ce que l'ensemble du courant de gaz de synthèse D, comprenant une fraction de produit, sortant du deuxième lit catalytique (1-B), est introduit dans le troisième lit catalytique (3-A).
  7. Procédé selon l'une quelconque des revendications précédentes, caractérisé en ce que le gaz de synthèse frais A est fabriqué par reformage d'hydrocarbures, le reformage ayant lieu dans un reformeur à vapeur, dans un reformeur chauffé par un gaz, dans un reformeur autotherme ou par oxydation partielle, ou en ce que le gaz de synthèse frais A est fabriqué par électrolyse d'eau et décomposition d'air.
  8. Procédé selon l'une quelconque des revendications précédentes, caractérisé en ce que la synthèse a lieu à une échelle qui dépasse une production quotidienne de 1 800 t, de préférence de 2 500, de manière particulièrement préférée de 3 000 t de produit.
  9. Dispositif pour la fabrication d'ammoniac à partir d'un gaz de synthèse (A) sous catalyse gazeuse hétérogène, notamment destiné à une utilisation dans un procédé selon l'une quelconque des revendications 1 à 8, le dispositif comprenant les composants suivants reliés les uns avec les autres par une liaison fonctionnelle :
    un premier dispositif de réaction (1), comprenant :
    un premier lit catalytique (1-A) configuré pour la formation d'un gaz de synthèse B comprenant un produit et des réactifs non réagis à partir d'un gaz de synthèse frais A ;
    un premier échangeur de chaleur (1-2) configuré pour le chauffage du gaz de synthèse frais A avant l'entrée dans le premier lit catalytique (1-A) et pour le refroidissement d'un gaz de synthèse B après la sortie du premier lit catalytique (1-A) ;
    un deuxième lit catalytique (1-B) configuré pour la formation d'un gaz de synthèse D comprenant un produit et des réactifs non réagis à partir du gaz de synthèse B ;
    un moyen configuré pour le déchargement du gaz de synthèse D du premier dispositif de réaction (1) ;
    un échangeur de chaleur intermédiaire (2-1) configuré pour le refroidissement d'au moins une partie du gaz de synthèse D ;
    un deuxième dispositif de réaction (3) comprenant :
    un troisième lit catalytique (3-A) configuré pour la formation d'un gaz de synthèse F comprenant un produit et des réactifs non réagis à partir du gaz de synthèse E ;
    un troisième échangeur de chaleur (3-2) configuré pour le chauffage du gaz de synthèse E avant l'entrée dans le troisième lit catalytique (3-A) et pour le refroidissement du gaz de synthèse F après la sortie du troisième lit catalytique (3-A) ;
    un quatrième lit catalytique (3-B) configuré pour la formation d'un gaz de synthèse H comprenant un produit et des réactifs non réagis à partir du gaz de synthèse F ;
    un moyen configuré pour le déchargement du gaz de synthèse H du deuxième dispositif de réaction (3) ; et
    un échangeur de chaleur secondaire (4-1) configuré pour le refroidissement d'au moins une partie du gaz de synthèse H, caractérisé en ce que le premier échangeur de chaleur (1-2) est agencé de manière concentrique radiale à l'intérieur du premier lit catalytique (1-A) et/ou le troisième échangeur de chaleur (3-2) est agencé de manière concentrique radiale à l'intérieur du troisième lit catalytique (3-A).
  10. Dispositif selon la revendication 9, caractérisé en ce que
    - le premier échangeur de chaleur (1-2) ; et/ou
    - l'échangeur de chaleur intermédiaire (2-1) ; et/ou
    - le troisième échangeur de chaleur (3-2) ; et/ou
    - l'échangeur de chaleur secondaire (4-1) sont chacun indépendamment les uns des autres configurés sous la forme d'un échangeur de chaleur à tube droit, à tube en U ou à plaques.
  11. Dispositif selon l'une quelconque des revendications 9 ou 10, caractérisé en ce que le dispositif comprend en outre :
    un moyen configuré pour le recyclage d'au moins une partie du gaz de synthèse H depuis l'échangeur de chaleur secondaire (4-1) dans le premier dispositif de réaction (1) .
  12. Dispositif selon l'une quelconque des revendications 9 à 11, caractérisé en ce que le dispositif comprend en outre :
    un moyen configuré pour le chauffage d'eau, qui est acheminée dans l'échangeur de chaleur intermédiaire (2-1) et/ou dans l'échangeur de chaleur secondaire (4-1) pour la formation de vapeur et/ou pour le préchauffage supplémentaire de l'eau.
  13. Dispositif selon l'une quelconque des revendications 9 à 12, caractérisé en ce que celui-ci comprend un lit catalytique supplémentaire (1-C ou 3-C), qui est agencé dans le premier dispositif de réaction (1) en aval du deuxième lit catalytique (1-B) ou dans le deuxième dispositif de réaction (3) en aval du quatrième lit catalytique (3-B).
  14. Dispositif selon l'une quelconque des revendications 9 à 13, caractérisé en ce que celui-ci comprend, dans le premier dispositif de réaction (1), au moins trois lits catalytiques agencés en série dans la direction d'écoulement du courant de gaz de synthèse et/ou, dans le deuxième dispositif de réaction (3), au moins trois lits catalytiques agencés en série dans la direction d'écoulement du courant de gaz de synthèse.
  15. Dispositif selon l'une quelconque des revendications 9 à 14, caractérisé en ce que le premier échangeur de chaleur (1-2) est agencé dans le premier dispositif de réaction (1) de telle sorte qu'il soit tout d'abord traversé par le gaz de synthèse frais A, avant que celui-ci n'entre dans le premier lit catalytique (1-A), et de telle sorte qu'il soit de préférence traversé à contre-courant par le gaz de synthèse B sortant du premier lit catalytique (1-A), qui comprend un produit et des réactifs non réagis, après la sortie du premier lit catalytique (1-A) et avant l'entrée dans le deuxième lit catalytique (1-B).
  16. Dispositif selon l'une quelconque des revendications 9 à 15, caractérisé en ce que le troisième échangeur de chaleur (3-2) est agencé dans le deuxième dispositif de réaction (3) de telle sorte qu'il soit tout d'abord traversé par le gaz de synthèse C quittant le premier dispositif de réaction (1), avant que celui-ci n'entre dans le troisième lit catalytique (3-A), et de telle sorte qu'il soit de préférence traversé à contre-courant par le gaz de synthèse sortant du troisième lit catalytique (3-A), qui comprend un produit et des réactifs non réagis, après la sortie du troisième lit catalytique (3-A) et avant l'entrée dans le quatrième lit catalytique (3-B).
  17. Dispositif selon l'une quelconque des revendications 9 à 16, caractérisé en ce qu'un premier échangeur de chaleur préliminaire (1-1) est prévu, afin de préchauffer le gaz de synthèse frais A.
  18. Dispositif selon l'une quelconque des revendications 16 ou 17, caractérisé en ce qu'un deuxième échangeur de chaleur préliminaire (3-1) est prévu, afin de préchauffer le gaz de synthèse C ou D.
EP17722691.7A 2016-04-18 2017-04-13 Configuration de la synthèse de nh3 pour de grandes installations Active EP3416916B1 (fr)

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DE102016107124.2A DE102016107124A1 (de) 2016-04-18 2016-04-18 NH3 Synthesekonfiguration für Großanlagen
PCT/EP2017/058933 WO2017182385A1 (fr) 2016-04-18 2017-04-13 Configuration de la synthèse de nh3 pour de grandes installations

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DE102018129639A1 (de) * 2018-11-23 2020-05-28 Thyssenkrupp Ag Vorrichtung und Verfahren zur katalytischen Herstellung von Ammoniak aus Synthesegas
DE102019218350A1 (de) * 2019-11-27 2021-05-27 Thyssenkrupp Ag Verfahren und Anlage zur Herstellung von Ammoniak
EP4269345A1 (fr) * 2022-04-29 2023-11-01 Linde GmbH Procédé et réacteur de conversion catalytique d'un courant d'alimentation

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DD225029A3 (de) 1982-12-10 1985-07-17 Bendix Horst Dieter Verfahren zur energetisch guenstigen synthese von ammoniak
DE3343114C2 (de) 1983-11-29 1985-11-07 Uhde Gmbh, 4600 Dortmund Vorrichtung zur Durchführung exothermer, katalytischer Gasreaktionen für die Ammoniak- oder Methanol-Synthese
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US20190106330A1 (en) 2019-04-11
US10618817B2 (en) 2020-04-14
DE102016107124A1 (de) 2017-10-19
CN109071248A (zh) 2018-12-21

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